Multi-Layer Coalescing Media Porosity Gradient
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coalescing systems face challenges in efficiently removing smaller droplets of dispersed phases from continuous phases, particularly in fuels with lower interfacial tensions, such as ultra-low sulfur diesel and biodiesels, which require enhanced coalescence to protect high-pressure rail fuel-injection systems and allow for smaller media packs.
Innovation Solution
The coalescing media is configured with at least three adjacent layers of varying porosity, mean flow pore diameters, and capillary pressures, where the second layer has a higher porosity and pore diameter than the first and third layers, facilitating droplet coalescence and growth, and potentially includes additional layers for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coalescing media with graded capture (decreasing fiber diameter, pore size and/or porosity) or thick depth coalescers are used, then droplet capture and coalescence are enhanced, but the media pack size increases and removal efficiency for smaller droplets remains insufficient
Solution Approach 1:
The coalescing media is divided into multiple discrete layers, each with specific porosity and pore size characteristics. The layers are arranged in a sequence (high porosity layer, intermediate porosity layer, low porosity layer) to create staged droplet capture and coalescence zones, allowing efficient removal of small droplets without requiring excessive media depth.
Solution Approach 2:
Different regions of the coalescing media have different porosity and pore size properties tailored to specific functions. The high porosity layer provides initial droplet capture with minimal pressure drop, the intermediate layer facilitates coalescence, and the low porosity layer ensures final separation, optimizing overall performance while minimizing media volume.
2Adaptability or versatility
If fuels with lower interfacial tensions (ULSD, biodiesel) are used, then fuel quality and emissions are improved, but droplet size decreases making coalescence more difficult
Solution Approach 1:
The coalescing media parameters (porosity, pore size, layer thickness) are specifically optimized to handle the smaller droplet sizes characteristic of ULSD and biodiesel fuels. The multi-layer structure with controlled pore gradients creates appropriate capillary pressure differentials to capture and coalesce these finer droplets that result from lower interfacial tensions in modern fuels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration achieves high efficiency in removing at least 93% of the dispersed phase, with embodiments capable of removing up to 99% of water dispersed in hydrocarbon fuel, by concentrating and coalescing droplets effectively, even in challenging fuel compositions.
Implementation Method 1
The first layer, the second layer, and the third layer have capillary pressures, P1, P2, and P3, respectively, and P2>P3 and P2>P1
Implementation Method 2
The first layer, the second layer, and the third layer have porosities ε1, ε2, and ε3, respectively, and ε2>ε1 and ε2>ε3
Data Source
AI summary
Disclosed are coalescing media for coalescing a mixture of two phases, namely a continuous phase and a dispersed phase. The disclosed coalescing media has multiple layers with distinct porosities, where an interior layer of the coalescing media has a higher porosity than the layers immediately adjacent to the interior layer. The disclosed media may be utilized in coalescers, coalescing systems, or coalescing methods for removing the dispersed phase from the mixture.